2003 FORD MUSTANG check transmission fluid

Pinpoint Tests
The pinpoint tests are a step-by-
step diagnostic process designed to determine the cause of a z
Bump—occurs
when shifting
from PARK to
a drive or
reverse
position.
Similar to
Clunk but with
no sound z
Initial gear
engagement. z
Acceptable condition.
z Buzz or hiss zIncorrect driveline
angles. z
CHECK for correct driveline
angles. REPAIR as
necessary. REFER to Section 205 - 00 .
z Worn or damaged
main control
solenoids or valves. z
Using a transmission tester,
ACTIVATE the solenoids to
duplicate sound. INSTALL
new components as
necessary. REFER to Section 307 - 01 .
z Vibration— a
high frequency
(20–80 Hz) that
is felt through
the seat or
gear shifter.
Changes with
engine speed z
Transmission cooler
lines grounded out. z
CHECK the transmission
cooler lines. REPAIR as
necessary.
z Flexplate to torque
converter nuts loose. z
CHECK the flexplate nuts.
TIGHTEN to specification.
REFER to Section 307 - 01 .
z Fluid filler tube
grounded out. z
CHECK the fluid filler tube.
REPAIR as necessary.
z Shift cable incorrectly
routed, grounded out
or loose. z
CHECK the shift cable.
REPAIR as necessary.
Section 307 - 05 .
z Shutter or
chatter—
occurs with
light to medium
acceleration
from low
speeds or a
stop z
Electrical
inputs/outputs.
z Vehicle wiring
harness.
z Incorrect
inputs/outputs from
the powertrain control
module (PCM), digital
transmission range
(TR) sensor, brake
pedal position (BPP)
sensor, throttle
position (TP) sensor,
transmission speed
sensor (TSS), output
speed shaft (OSS)
sensor or the torque
converter clutch
(TCC). z
CARRY OUT a Torque
Converter Clutch Operation
Test. RUN on- board
diagnostics or self- test.
REFER to Section 307 - 01 .
CLEAR the DTC's, ROAD
TEST and RERUN on- board
diagnostics or self- test. Klj . 47 ba
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PINPOINT TEST M: TRANSFER CASE VIBRATION the system for normal operation.
No
GO to
L6 .
L6 CHECK THE FLYWHEEL BOLTS
z
Check for loose flywheel bolts.
z Are the bolts loose? Yes
TIGHTEN the bolts to
specifications. REFER to
Section 308 - 01 . TEST the system for
normal operation.
No
GO to L7 .
L7 CHECK THE FLYWHEEL SURFACE
z
Inspect the flywheel surface for wear or damage.
Check the flywheel runout.
z Is there any damage or excessive wear? Yes
INSTALL a new flywheel. TEST
the system for normal operation.
No
Clutch system normal. CONDUCT
a diagnosis on other suspect
systems.
Test Step Result / Action to Take
M1 INSPECT THE TRANSFER CASE
z
WARNING: The electrical power to the air suspension
system must be shut off prior to hoisting, jacking or towing
an air suspension vehicle. This can be accomplished by
turning off the air suspension switch. Failure to do so can
result in unexpected inflation or deflation of the air springs,
which can result in shifting of the vehicle during these
operations.
z Inspect the transfer case for loose or missing mounting bolts.
Check for fluid seepage between the transfer case and the
transmission.
z Are the mounting bolts missing or loose? Yes
TIGHTEN to
specifications or
INSTALL new bolts as
necessary. TEST the
system for normal
operation.
No
GO to
M2 .
M2 INSPECT THE REAR DRIVESHAFT
z
NOTE: Verify that the driveshaft and pinion flange index marks
are aligned.
z Inspect the driveshaft for missing weights, damage or
undercoating.
z Inspect the U- joints for freedom of movement.
z Check driveshaft runout and, if necessary, check the pinion
flange runout.
z Is the driveshaft or U- joints worn or damaged or
misaligned? Yes
REPAIR or INSTALL a
new driveshaft as
necessary. TEST the
system for normal
operation.
No
GO to
M3 .
M3 CHECK THE DRIVELINE ANGLES
z
Measure the rear driveshaft and pinion angles. Refer to Section 205 - 00 .
z Measure the front driveshaft and pinion angles. Refer to Section 205 - 00 .
z Are the driveline angles incorrect? Yes
REPAIR as necessary.
TEST the system for
normal operation.
No Klj . 62 ba
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Component Tests
Brake Booster
1. Check the hydraulic brake system for leaks or insufficient fluid.
2. With the transmission (7003) in NEUTRAL, stop the engine (6007) and apply the parking brake control (2780). Apply the brake pedal several times to exhaust all vacuum in the system.
3. Apply the brake pedal and hold it in the applied position. Start the engine. If the vacuum system is operating, the brake pedal will tend to move downward under constant foot pressure. If no
motion is felt, the power brake booster system is not functioning. Continue with the following
steps.
4. Remove the vacuum booster hose from the check valve connection. Manifold vacuum must be available at the check valve end of the vacuum booster hose with the engine at idle speed and
the transmission in NEUTRAL. If the manifold vacuum is available to the power brake booster,
connect the vacuum booster hose to the power brake booster check valve and repeat Steps 2
and 3.
5. If no downward movement of the brake pedal is felt, install a new power brake booster.
6. Operate the engine a minimum of 10 seconds at fast idle. Stop the engine, and let the vehicle stand for 10 minutes. Then apply the brake pedal with approximately 89 N (20 lb) of force. The
brake pedal feel should be the same as that noted with the engine operating. If the brake pedal
feels hard (no power assist), install a new power brake booster check valve and retest. If the
brake pedal feels spongy, bleed the hydraulic system to remove air. For additional information,
refer to Bleeding — System in this section. Check Valve z
Engine running at idle speed.
z CAUTION: Do not hold the brake pedal at 444 Nm
(100 lb) force for more than 5 seconds at a time.
z Apply brake pedal with approximately 444 Nm (100 lb)
force and hold.
z Check hydro-boost unit input seal, housing seal,
accumulator seal, piston seal and spool plug seal for
leakage.
z Is hydro- boost unit free of leaks? Yes
GO to
G6 .
No
INSTALL a new hydro- boost
unit. G6 CHECK RESERVE RETENTION
z
Engine running at idle speed.
z CAUTION: Do not hold the brake pedal at 444 Nm
(100 lb) force for more than 5 seconds at a time.
z Charge system to pressure by holding the steering wheel at
stop or by pressing the brake pedal with approximately 444
Nm (100 lb) force.
z Key in OFF position.
z Wait five seconds.
z Press brake pedal and observe if there is any power brake
reserve.
z Is there any power brake reserve? Yes
Hydro-
boost unit is OK.
No
INSTALL a new hydro- boost
unit. Klj . 13 ba
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z
On some vehicles, the power steering pump high pressure port is inaccessible and the
special tool should then be installed either at the steering gear or at a point in the high
pressure line between the power steering pump and the steering gear.
2. Place a dial thermometer in the power steering pump reservoir.
3. Check the power steering fluid level. If necessary, add power steering fluid. zUse Motorcraft MERCON® Multi-Purpose ATF XT -2-QDX or MERCON® equivalent.
4. Install a digital tachometer.
5. CAUTION: Do not hold the steering wheel against the stops for more than three to
five seconds at a time. Damage to the power steering pump will occur.
Start the engine. Place the transmission in neutral. Set the parking brake. Raise the power
steering fluid temperature to 74- 80°C (165-175°F) by rotating the steering wheel fully to the left
and right several times.
6. Set the engine speed to 1500 rpm. Record the flow rate and pressure readings. zIf the flow rate is below the flow rate specification, a new power steering pump may need
to be installed. Continue with the test procedure.
z If the pressure reading is above the maximum pressure specification, then check power
steering hoses for kinks and restrictions.
7. Partially close the gate valve to obtain 750 psi. Set the engine speed at idle. Record the flow rate.
zIf the flow is less than the specified flow rate, then install a new power steering pump. For
additional information, refer to Section 211 - 02 .
8. CAUTION: Do not allow the gate valve to remain closed for more than 5 seconds.
Completely close and partially open the gate valve 3 times. Record the pressure relief valve
actuation pressure reading. zIf the pressure does not meet the relief pressure specification, install a new power
steering pump. For additional information, refer to Section 211 - 02 .
9. Set engine speed to 1500 rpm. Record the flow rate. zIf the flow rate varies more than 3.785 liters/minute (1 gallon/minute) from the initial flow
rate reading, install a new power steering pump. For additional information, refer to
Section 211 - 02 .
10. CAUTION: Do not hold the steering wheel against the stops for more than three to
five seconds at a time. Damage to the power steering pump will occur.
Set the engine speed at idle. Turn (or have an assistant turn) the steering wheel to the left and
right stops. Record flow rate and pressure readings at the stops.
zThe pressure reading at both stops should be nearly the same as the maximum pump
relief pressure.
z The flow rate should drop below 1.9 liters/minute (0.5 gallons/minute).
z If the pressure does not reach the maximum pump relief pressure or the flow rate does
not drop below the specified value, excessive internal leakage is occurring. Install a new
steering gear as necessary. For additional information, refer to Section 211 - 02 . Klj . 9 ba
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DIAGNOSIS AND TESTING
Engine Cooling
Inspection and Verification
WARNING: Never remove the pressure relief cap while the engine is operating or when the
cooling system is hot. Failure to follow these instructions can result in damage to the cooling
system or engine or personal injury. To avoid having scalding hot coolant or steam blow out of
the degas bottle when removing the pressure relief cap, wait until the engine is cooled, then
wrap a thick cloth around the pressure relief cap and turn it slowly. Step back while the
pressure is released from the cooling system. When you are sure all the pressure has been
released, turn and remove the pressure relief cap (still with a cloth).
CAUTION: Check the coolant level, engine oil and transmission fluid, top off the coolant if
needed. If there is engine coolant in the engine oil or transmission fluid, the cause must be
corrected and oil/fluid changed or major component damage may occur.
1. Verify the customer's concern by operating the engine to duplicate the condition.
2. Inspect to determine if any of the following mechanical or electrical concerns apply.
SECTION 303-
03A: Engine Cooling 2003 Mustang Workshop Manual Special Tool(s)
Pressure Tester
014-
R1072 or equivalent 73III Automotive Meter
105-
R0057 or equivalent Worldwide Diagnostic System
(WDS)
418-
F224,
New Generation STAR (NGS)
Tester
418- F052, or equivalent scan
tool Battery/Anti-Freeze Tester
014- R1060 or equivalent Klj . 1 ba
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while the pressure is released from the cooling system.
When you are sure all the pressure has been released, turn
and remove the pressure relief cap (still with a cloth).
NOTE:
Allow the engine to cool before checking the engine
coolant level.
z Key in OFF position.
z Visually check the engine coolant level at the degas bottle or
coolant expansion tank.
z Is the engine coolant level within specification? A2 CHECK THE PRESSURE RELIEF CAP
z
Carry out the Cap— 3.8L or Cap—4.6L test. Go to Component
Tests in this section.
z Is pressure relief cap/radiator cap OK? Yes
GO to
A3 .
No
INSTALL a new
pressure relief
cap/radiator cap. TEST
the system for normal
operation. A3 CHECK THE ENGINE COOLANT FOR INTERNAL LEAK
z
Key in OFF position.
z Inspect the engine coolant in degas bottle/coolant expansion
tank for signs of transmission fluid or engine oil.
z Is oil or transmission fluid evident in the coolant? Yes
If engine oil is evident,
REFER to
Section 303 -
00 . If transmission fluid
is evident, REPAIR or
INSTALL a new radiator
as necessary.
No
GO to A4 .
A4 CHECK THE ENGINE AND THE TRANSMISSION FOR
COOLANT z
Remove the oil level dipstick from the engine and the
transmission.
z Is coolant evident in the oil or transmission fluid? Yes
If coolant is in engine,
REFER to
Section 303 -
00 . If coolant is in
transmission, REPAIR
or INSTALL a new
radiator as necessary.
To repair the automatic
transmission, REFER to
Section 307 - 01 .
No
GO to A5 .
A5 PRESSURE TEST THE ENGINE COOLING SYSTEM
z
Pressure test the engine cooling system. Go to Component
Tests in this section.
z Does the engine cooling system leak? Yes
REPAIR or install new
components. TEST the
system for normal
operation.
No
The cooling system is
operational. GO to
Symptom Chart
. Klj . 4 ba
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SPECIFICATIONS
a
MERCON® V is not interchangeable at this time with the current MERCON® fluids. Check the
transmission fluid level indicator to determine the correct fluid and refer to the Workshop/Owner
publication to determine the correct service interval for the specific vehicle. SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual General Specifications
Item Specification
Fluid
a Motorcraft MERCON® V Transmission Fluid XT
-5-QM MERCON®
V Fluid Capacities
3.8L engine 13.2L (13.9 quarts)
4.6L engine 12.0L (12.8 quarts)
Fluid Filter
Inline Transmission Fluid Filter Kit XC3Z-
7B155- AA Inline Transmission Fluid Filter XC3Z-
7B155- BA Lubricant
Ford Multi-Purpose Grease D0AZ-19584-
AA ESB-
M1C93- B
Torque Converter End Play Item Specification
New or remanufactured 0.355-
1.04 mm (0.014- 0.074 in) Used 0.355-
1.87 mm (0.014- 0.074 in)
Band and Clutch Application Chart Gear Overdrive
Band Low
Reverse Band Forward
Clutch Direct
Clutch Interm
Friction Clutch Reverse
Clutch Interm
One-Way
Clutch Planetary
One- Way
Clutch 1st Gear
Manual Low A A H
2nd Gear
Manual Low A A A H
1st Gear —
(D)
(Overdrive) A H
2nd Gear —
(
D)
(Overdrive) A A H
3rd Gear —
(
D)
(Overdrive) A A A O/R
4th Gear —
(
D) A A A O/R Klj . 1 ba
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DIAGNOSIS AND TESTING
Diagnostic Strategy
Troubleshooting an electronically controlled automatic transmission is simplified by using the proven
method of diagnosis. One of the most important things to remember is that there is a definite
procedure to follow.
NOTE:
Do not take any short cuts or assume that critical checks or adjustments have already been
made.
Follow the procedures as written to avoid missing critical components or steps.
To properly diagnose a concern have the following publications available:
zTransmission Reference Manual.
z Powertrain Control/Emissions Diagnosis (PC/ED) manual.
z TSBs and OASIS Messages.
z Wiring Diagram.
These publications provide the information required when diagnosing transmission concerns.
Use the Diagnostic Flow Chart as a guide and follow the steps as indicated.
Preliminary Inspection
zKnow and understand the customer's concern.
z Verify the concern by operating the vehicle.
z Check the fluid levels and condition.
z Check for non-factory add- on items.
z Check shift linkages for proper adjustment.
z Check TSBs and OASIS messages regarding the concern.
Diagnostics
zCarry out on- board diagnostic procedures key on engine off (KOEO) and key on engine running
(KOER).
z Record all diagnostic trouble codes (DTCs).
z Repair all non- transmission codes first.
z Repair all transmission codes second.
z Erase all continuous codes and attempt to repeat them.
z Repair all continuous codes.
z If only pass codes are obtained, refer to Diagnosis By Symptom for further information and
diagnosis.
Follow the diagnostic sequence to diagnose and repair the concern the first time. SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Klj . 1 ba
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